Frame assembly and a method of manufacturing the same

ABSTRACT

A frame assembly supports an article. The frame assembly comprises a frame member having a plurality of walls extending between a first end and a second end. The walls define an interior of the frame member. The frame assembly also comprises at least one foldable cornerlock. The foldable cornerlock has first and second body portions movable relative to each other. A method of manufacturing the frame assembly comprises the steps of forming at least one notch in the frame member spaced from the ends of the frame member, inserting the foldable cornerlock into the notch, and bending the frame member about the notch of the frame member.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to and all the advantages of U.S.Provisional Patent Application No. 61/211,205 filed on Mar. 27, 2009,which is incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention generally relates to a frame assembly for receiving anarticle and to a method of manufacturing the frame assembly. Morespecifically, the invention relates to a foldable cornerlock for use inthe frame assembly and the method of manufacturing the frame assembly.

2. Description of the Related Art

Frame assemblies for supporting an article are known in the art and havebeen widely used by window manufacturers. The article supported by theframe assembly may be a fenestration article, such as a screen cloth orpane of glass.

The frame assemblies include at least one frame member. The frame memberhas four walls presenting a rectangular cross-section of the framemember. The walls of the frame member impart the frame member withstrength and rigidity. The frame member also has a first end and asecond end spaced from the first end. The frame assemblies of the priorart are either a multiple frame member frame assembly or a single framemember frame assembly. A common multiple frame member frame assembly hasfour of the frame members. Four coupling cornerlocks are used to securethe frame members together to present a rectangular configuration.During manufacturing of the multiple frame member frame assembly, eachof the frame members must be individually produced. More specifically,each of the frame members must be cut to a desired length.

The single frame member frame assembly includes only one frame memberwith the walls of the frame member defining three notches. The framemember is bent at the notches to present a rectangular configuration ofthe frame member and results in the ends of the frame member beingadjacent each other. The ends of the frame member are secured togetherwith one of the coupling cornerlocks. A bracket is mounted to anexterior of the frame member at each of the corners for reinforcing theframe member at the corners. The inclusion of the bracket requiresadditional time and increases the cost to manufacture the single framemember frame assembly. Additionally, because the bracket is coupled tothe exterior of the frame member, the bracket results in an appearanceof the exterior of the frame member that is aesthetically unpleasing.

Therefore, there remains a need to provide an improved frame assemblyand method of manufacturing the frame assembly.

SUMMARY OF THE INVENTION AND ADVANTAGES

A frame assembly supports an article. The frame assembly comprises aframe member. The frame member has a plurality of walls extendingbetween a first end and a second end, which is spaced from the firstend. The walls define an interior of the frame member. The frameassembly also comprises at least one foldable cornerlock. The foldablecornerlock has first and second body portions movable relative to eachother. A method of manufacturing the frame assembly comprises the stepsof forming at least one notch in the frame member spaced from the endsof the frame member and inserting the foldable cornerlock into the notchsuch that the body portions of the foldable cornerlock extend into theinterior of the frame member. The method also comprises the step ofbending the frame member about the notch to define a corner of the framemember.

Inserting the foldable cornerlock into the notch reinforces the framemember at notch. Additionally, an appearance of an exterior the framemember can be unaffected by the inclusion of the foldable cornerlock inthe frame assembly because the body portions of the foldable cornerlockextend into the interior of the frame member and are not coupled to theexterior of the frame member.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated,as the same becomes better understood by reference to the followingdetailed description, when considered in connection with theaccompanying drawings wherein:

FIG. 1 is a perspective view of a frame assembly having an articlespaced from a frame member;

FIG. 2 is a perspective view of the frame member illustrating walls ofthe frame member defining three notches;

FIG. 3 is an enlarged perspective view of a portion of the frame memberof FIG. 2 illustrating the walls of the frame member defining one notch;

FIG. 4 is a front view of a foldable cornerlock having first and secondbody portions;

FIG. 5 is a top view of the foldable cornerlock of FIG. 4;

FIG. 6 is a perspective view of the foldable cornerlock with the bodyportioned in a locked position;

FIG. 7 is another perspective view of the foldable cornerlock;

FIG. 8 is a perspective view of the foldable cornerlock spaced from theframe member with the body portions in a pre-inserted position;

FIG. 9 is a perspective view of a portion of the frame member with thefoldable cornerlock within the notch of the frame member and the bodyportions of the foldable cornerlock in the pre-inserted position;

FIG. 9A is the perspective view of FIG. 9 with the frame member partialcut away to reveal the cornerlock within an interior of the framemember;

FIG. 10 is a perspective view of a portion of the frame member with thefoldable cornerlock within the notch of the frame member;

FIG. 10A is the perspective view of FIG. 10 with the frame memberpartial cut away to reveal the cornerlock within the interior of theframe member;

FIG. 11 is a perspective view of a portion of the frame member with thefoldable cornerlock within the notch of the frame member and the bodyportions of the foldable cornerlock in an inserted position;

FIG. 11A is the perspective view of FIG. 11 with the frame memberpartial cut away to reveal the cornerlock within the interior of theframe member;

FIG. 12 is a perspective view of a portion of the frame member with thefoldable cornerlock within the notch illustrating the frame memberbending at the notch; and

FIG. 13 is a perspective view of a portion of the frame member when theframe member is bent to form a corner of the frame member with thefoldable cornerlock inserted within the notch of the frame member.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT

Referring to the Figures, wherein like numerals indicate correspondingparts throughout the several views, a frame assembly 20 is generallyshown. Although not required, the frame assembly 20 is typically coupledto a structure, such as a building or a house as part of a window ordoor assembly. It is to be appreciated that the frame assembly 20 may bedisposed within an interior of the structure or an exterior of thestructure. A method of manufacturing the frame assembly 20 is disclosedherein.

With reference to FIG. 1, the frame assembly 20 has a perimeterpresenting a rectangular configuration. It is to be appreciated that theframe assembly 20 may present other configurations such as a triangularconfiguration, or a pentagonal configuration. The frame assembly 20 maycomprise an article 22, with the frame assembly 20 supporting thearticle 22. The article 22 is attached to the frame member 24. It is tobe appreciated that the article 22 may be a fenestration article, suchas a screen cloth as shown in FIG. 1, a glass pane, or a plastic panelwith the fenestration article coupled to the frame assembly 20.Alternatively, the article 22 may be a picture, or a painting. However,it should be understood that the frame assembly 20 may support anydesired article.

The frame assembly 20 comprises a frame member 24. It is to beappreciated that the frame member 24 may be made from any suitablematerial, such as metal, and/or plastic. It is also to be appreciatedthat the frame member 24 may be formed by any suitable processincluding, but not limited to molding, roll forming, and/or extruding.With reference to FIG. 2, the frame member 24 has an entire length Lwhich is typically equal to the perimeter of the frame assembly 20 suchthat there is only one frame member 24. However, it is to be appreciatedthat the frame assembly 20 may comprise more than one frame member 24.The frame member 24 has a plurality of walls 26A-26D extending between afirst end 28 and a second end 30 spaced from said first end 28. Thewalls 26A-26D impart strength and rigidity to the frame member. Thewalls 26A-26D define an interior 32 of the frame member 24. Although notrequired, the interior 32 of the frame member 24 may be hollow. However,it is to be appreciated that the frame member 24 does not have to becompletely hollow and can be formed as a solid component with hollowedout portions.

With reference to FIGS. 2 and 3, in one embodiment, the frame member 24has a rectangular cross-section. In such an embodiment, the plurality ofwalls 26A-26D are further defined as a top wall 26A, a bottom wall 26Bspaced opposite from the top wall 26A, an exterior wall 26Cinterconnecting the top wall 26A and the bottom wall 26B, and aninterior wall 26D spaced opposite from the exterior wall 26C andinterconnecting the top wall 26A and the bottom wall 26B. It is to beappreciated that the frame member 24 may have other cross-sections, suchas a triangular cross-section. When the frame assembly is coupled to thestructure the interior wall 26D faces the interior of the structure andthe exterior wall 26C faces the exterior of the structure.

The method comprises the steps of forming at least one notch 34A-34C inthe frame member 24 spaced from the ends 28, 30 of the frame member 24.The walls 26A-26D of the frame member 24 define the notch 34A-34C. Atleast one of the walls 26A-26D is continuous over the entire length L ofthe frame member 24. For example, the notch 34A-34C extends through thetop wall 26A, the exterior wall 26C and the interior wall 26D such thatthe bottom wall 26B is continuous over the entire length L of the framemember 24. It is to be appreciated that the notch 34A-34C may be formedin the frame member 24 by any suitable method, such as cutting, and/orstamping.

The frame member 24 is bendable at the notch 34A-34C to form a corner 36of the frame member 24. The method includes the step of bending theframe member 24 about the notch 34A-34C to define a corner 36 of theframe member 24. The formation of the notch 34A-34C in the frame member24 weakens the frame member 24 at the notch 34A-34C. Said differently,the notch 34A-34C results in an absence of a portion of the walls26A-26D of the frame member 24 which reduces the strength and rigidityof the frame member 24 at the notch 34A-34C. The weakening of the framemember 24 at the notch 34A-34C allows the frame member 24 to be bent atthe notch 34A-34C. The bending of the frame member 24 at the notch34A-34C brings the walls 26A-26D of the frame member 24 on either sideof the notch 34A-34C together. However, the walls 26A-26D on either sideof the notch 34A-34C generally do not contact each other therebydefining a groove between the walls 26A-26D of the frame assembly 20 oneither side of the notch 34A-34C after the frame member 24 is bent.

Bending the frame member 24 at the notch 34A-34C establishes a firstangle A1 as shown in FIG. 13. For example, if the frame member 24 is tohave the rectangular configuration, then the first angle A1 of the framemember 24 is approximately 90 degrees. Typically, the notch 34A-34Cpresents a general V-shape configuration defining a second angle A2.However, it is to be appreciated that the notch 34A-34C can presentother configurations, such as a U-shaped configuration. Generally, thesecond angle A2 is equal to the first angle A1 defined by the framemember 24.

In one embodiment, the at least one notch 34A-34C may be further definedas a first notch 34A, a second notch 34B, and a third notch 34C witheach of the notches 34A, 34B, 34C spaced from each other and from theends 28, 30 of the frame member 24, as shown in FIG. 2. It is to beappreciated that each of the first notch 34A, the second notch 34B, andthe third notch 34C are defined by the walls 26A-26D of the frame member24. As such, it is to be appreciated that the step of forming at leastone notch 34A-34C in the frame member 24 may be further defined asforming the first notch 34A, the second notch 34B, and the third notch34C in the frame member 24 with each of the notches 34A-34C spaced fromeach other and from the ends 28, 30 of the frame member 24. If the firstnotch 34A, the second notch 34B, and the third notch 34C are present,then the frame member 24 is bent about the first notch 34A, the secondnotch 34B, and the third notch 34C to present the frame assembly 20 witha rectangular configuration. However, it should be appreciated that thenumber of notches 34A-34C defined by the frame member 24 may be changedresulting in the frame member 24 presenting other configurations such asthe triangular or pentagonal configurations as described above.

The method may also comprise the step of coupling the ends 28, 30 of theframe member 24 together with the coupling cornerlock 40. The couplingcornerlock 40 is included in the frame assembly 20 and is disposed ineach of the ends 28, 30 of the frame member 24 for coupling the ends 28,30 of the frame member 24 together. It is to be appreciated that theends 28, 30 of the frame member 24 may be coupled together by anysuitable method and/or device. For example, a fixed or bendablecornerlock may be used to couple the ends 28, 30. Bending the framemember 24 about the first notch 34A, the second notch 34B, and the thirdnotch 34C results in the ends 28, 30 of the frame member 24 beingadjacent to each other such that the coupling cornerlock 40 can engageeach of the ends 28, 30 for securing the ends 28, 30 together. If thecoupling cornerlock 40 is utilized, then the ends 28, 30 of the framemember 24 may be cut at opposing angles for forming the corner 36 or,alternatively, the coupling cornerlock 40 may be the corner 36.

The frame assembly 20 may further comprise a flange 42 extending fromthe frame member 24 for securing the article 22 to the frame member 24.The flange 42 may be integral with the frame member 24 or, the flange 42may be a discrete component coupled to the frame member 24.Additionally, if the flange 42 is present, then the interior 32 of theframe member 24 may be defined by the walls 26A-26D of the frame memberand the flange 42. It is to be appreciated that the flange 42 is notrequired and the frame member 24 may support the article 22 by anysuitable method.

The frame assembly 20 also comprises at least one foldable cornerlock48. It is to be appreciated that the foldable cornerlock 48 may also bereferred to as a foldable corner key. The foldable cornerlock 48 isdescribed in co-pending U.S. patent application to Sawyers et al. filedon Mar. 26, 2010 entitled “Foldable Cornerlock for a Frame Assembly,”which claims priority to U.S. Provisional Application No. 61/211,205,and is hereby incorporated by reference. The method comprises the stepof inserting the foldable cornerlock 48 into the notch 34A-34C of theframe member 24. Generally, the foldable cornerlock 48 is inserted intothe notch 34A-34C prior to bending the frame member 24 at the notch34A-34C. The foldable cornerlock 48 is disposed in the notch 34A-34C ofthe frame member 24 and extends into the interior 32 of the frame member24. Typically, the foldable cornerlock 48 is made from a rigidthermoplastic, but could be made from a metal. The foldable cornerlock48 reinforces the frame member 24 at the notch 34A-34C. Saiddifferently, the foldable cornerlock 48 imparts strength and rigidity tothe frame member at the notch 34A-34C.

In one embodiment, the at least one foldable cornerlock 48 is furtherdefined as a first foldable cornerlock 48A, a second foldable cornerlock48B, and a third foldable cornerlock 48C disposed in the first notch34A, the second notch 34B and the third notch 34C, respectively. Inaddition to being utilized in the notches 34A-34C, the foldablecornerlock 48 may also be used to couple the ends 28, 30 of the framemember 24 together. When there are three notches 34A-34C and threefoldable cornerlocks 48A-48C, the first foldable cornerlock 48A isinserted into the first notch 34A, the second foldable cornerlock 48B isinserted into the second notch 34B, and the third foldable cornerlock48C is inserted into the third notch 34C such that each of the foldablecornerlocks 48A-48C extend into the interior 32 of the frame member 24.

The foldable cornerlock 48 comprises first and second body portions 50,52 movable relative to each other. The body portions 50, 52 of thefoldable cornerlock 48 extend into the interior 32 of the frame member24 when the foldable cornerlock 48 is inserted into the notch 34A-34C,The foldable cornerlock 48 may comprise a hinge portion 54 which couplesthe body portions 50, 52 together. The hinge portion 54 defines an axis56 extending in a longitudinal direction through the hinge portion 54.If the hinge portion 54 is present, then the body portions 50, 52 may berotatable about the axis 56 for inserting the foldable cornerlock 48into the notch 34A-34C of the frame member 24. It is to be appreciatedthat the body portions 50, 52 are not required to rotate a full 360degrees, any degree of rotation is sufficient. The body portions 50, 52of the foldable cornerlock 48 may be ridge for imparting rigidity to theframe member 24 at the corner 36. Said differently, if the body portions50, 52 are ridged then the body portions 50, 52 do not flex. The hingeportion 54 may be integral to the body portions 50, 52, such as a livinghinge. Alternatively, the hinge portion 54 may be a discrete componentto the body portions 50, 52 with the body portions 50, 52 mechanicallycoupled to the hinge portion 54.

The first and second body portions 50, 52 are each configured to matewith the interior 32 of the frame member 24 for preventing the foldablecornerlock 48 from shifting within the frame member 24. Saiddifferently, each of the body portions 50, 52 of the foldable cornerlock48 has a plurality of surfaces for contacting the walls 26A-26D of theframe member 24 within the interior 32 of the frame member 24. Forexample, if the frame member 24 includes the top wall 26A, the bottomwall 26B, the exterior wall 26C, and the interior wall 26D, then each ofthe body portions 50, 52 includes a top surface 58A for contacting thetop wall 26A, an opposing bottom surface 58B for contacting the bottomwall 26B, an exterior surface 58C for contacting the exterior wall 26Cand an opposing interior surface 58D for contacting the interior wall26D. The exterior surface 58C and interior surfaces 58D may betransverse to the top surface 58A and bottom surfaces 58B. Additionally,if the flange 42 is present, then the exterior surface 58C may extendbeyond the top surface 58A for engaging the interior 32 defined by theflange 42.

Each of the body portions 50, 52 have an end 60 spaced from the hingeportion 54. The bottom surface 58B extends from the hinge portion 54 tothe end 60 of the body portions 50, 52. Additionally, each of the bodyportions 50, 52 may comprise an abutting surface 62 extending from thehinge portion 54 to the top surface 58A.

With reference to FIG. 4, the end 60 of each of the body portions 50, 52has an arcuate configuration for sliding along the interior 32 of theframe member 24 as the foldable cornerlock 48 is inserted in the notch34A-34C. The arcuate configuration of the end 60 may continuously extendfrom the top surface 58A to the bottom surface 58B. Alternatively, onlya portion of the end 60 may have the arcuate configuration.

Each of the body portions 50, 52 may define a recess 64 for allowing thebody portions 50, 52 to be inserted into the notch 34A-34C of the framemember 24. Said differently, the recess 64 allows the body portions 50,52 of the foldable cornerlock 48 to slide past the walls 26A-26D of theframe member 24 defining the notch 34A-34C. The top surface 58A of eachof the body portions 50, 52 defines the recess 64.

The foldable cornerlock 48 may also comprise at least one arm member 66spaced in the longitudinal direction from one of the first and secondbody portions 50, 52 thereby defining a gap 68. As illustrated in FIG.10, the gap 68 receives one of the walls 26A-26D of the frame member 24when the foldable cornerlock 36 is disposed within the notch 34A-34C. Asthe frame member 24 is bent, one of the walls 26A-26D of the framemember 24 is received in the gap 68. Referring to FIG. 13, the armmember 66A, 66B cover the groove defined by the walls 26A-26D of theframe member 24 at the corner 36 to provide an aesthetically pleasingappearance.

The at least one arm member 66 may be further defined as a first armmember 66A and a second arm member 66B. The first arm member 66A isspaced in the longitudinal direction from the first body portion 50thereby defining a gap 68 for receiving one of the walls 26A-26D of theframe member 24, and the second arm member 66B spaced in thelongitudinal direction from one of the first and second body portions50, 52 thereby defining a second gap 70 for receiving one of the walls26A-26D of the frame member 24. However, the foldable cornerlock 48 mayinclude only one arm member 66. If the first and second arm members 66A,66B are both present, then the arm members 66A, 66B are spaced from eachother for allowing the frame member 24 to be disposed between the armmembers 66A, 66B. Disposing the frame member 24 between the arm members66A, 66B allows the arm members 66A, 66B to cover the walls 26A-26D ofthe frame member 24 at the corner 36. More specifically, the arm members66A, 66B cover the groove to present an aesthetically pleasingappearance. Additionally, the arm members 66A, 66B may impart additionalstrength and rigidity to the frame member 24 at the corner 36. The firstarm member 66A is spaced in the longitudinal direction from the exteriorsurface 58C of the body portions 50, 52 and the second arm member 66B isspaced in the longitudinal direction from the interior surface 58D ofthe body portions 50, 52.

The foldable cornerlock 48 may further comprise a first post 71extending from the first body portion 50 to the first arm member 66A forcoupling the first arm member 66A to the first body portion 50. If thesecond arm member 66B is present, then the foldable cornerlock 48 alsoincludes a second post 72 extending from the second body portion 52 tothe second arm member 66B for coupling the second arm member 66B to thesecond body portion 52. The first post 71 extends from the exteriorsurface 58C of the first body portion 50 and the second post 72 extendsfrom the interior surface 58D of the second body portion 52.

The foldable cornerlock 48 may comprise interlocking portions 74configured to engage each other for securing the body portions 50, 52together. The interlocking portions 74 reinforce the frame member 24 atthe corner 36 because the interlocking portions 74 prevent the bodyportions 50, 52 from moving relative to each other which facilitatesresistance of torsional forces that may act on the frame member 26. Theinterlocking portions 74 may comprise a female portion 76 defined by thefirst body portion 50 and a male portion 78 extending from the secondbody portion 52 configured to mate with the female portion 76. Theabutting surface 62 of the first body portion 50 defines the femaleportion 76 and the male portion 78 extends from the abutting surface 62of the second body portion 52. Alternatively, the female portion 76 maybe defined by the second body portion 52 and the male portion 78 mayextend from the first body portion 50.

As described above, the body portions 50, 52 of the foldable cornerlock48 are movable relative to each other. With reference to FIGS. 8-13, thebody portions 50, 52 may move between a pre-inserted position, aninserted position, and a locked position. Although the pre-insertedposition, inserted position, and the locked position have been describedwith the body portions 50, 52 moving relative to each other, it is to beappreciated that the movement may be rotation, with the body portions50, 52 rotating about the axis 56. Additionally, the body portions 50,52 may move in other ways, such as laterally. The foldable cornerlock 48may be positioned within the notch 34A-34C with the body portions 50, 52in the pre-inserted position such that the hinge portion 54 is spacedfrom the frame member 24.

As shown in FIGS. 9 and 9A, when the body portions 50, 52 are in thepre-inserted position, the body portions 50, 52 establish an acute anglerelative to each other. More specifically, when the body portions 50, 52are in the pre-inserted position, the bottom surface 26B of each of thebody portions 50, 52 establishes the acute angle relative to each other.

As shown in FIGS. 10 and 10A, when the body portions 50, 52 are in thepre-inserted position, the foldable cornerlock 48 is disposed within thenotch 34A-34C and the body portions 50, 52 are planar with each other.More specifically, when the body portions 50, 52 are in the pre-insertedposition, the bottom surface 26B of each of the body portions 50, 52 maybe planar with each other. Additionally, when the body portions 50, 52are in the pre-inserted position, the hinge portion 54 may contact theframe member 24 with the body portions 50, 52 extending into theinterior 32 of the frame member 24.

As shown in FIG. 13, when the body portions 50, 52 are in the lockedposition, the body portions 50, 52 establish a right angle relative toeach other. When the foldable cornerlock 48 is disposed within the notch34A-34C and the body portions 50, 52 are in the locked position, theframe member 24 is completely bent to form the corner 36 of the framemember 24. When the body portions 50, 52 are in the locked position, theabutting surface 62 of each of the body portions 50, 52 may contact eachother. It is to be appreciated that when the body portions 50, 52 are inthe pre-inserted position or the inserted position, the interlockingportions 74 are spaced from each other but, when the body portions 50,52 are in the locked position, the interlocking portions 74 engage eachother. If present, the interlocking portions 74 retain the foldablecornerlock 48 in the locked position once the interlocking portions 74engage each other. It is also to be appreciated that when the bodyportions 50, 52 are in the pre-inserted position or the insertedposition, the arm members 66A, 66B may extend longitudinally in anon-parallel direction relative to each other but, when the bodyportions 50, 52 are in the locked position, the arm members 66A, 66B mayextend longitudinally in a parallel direction relative to each other.

Generally, as the body portions 50, 52 move from the pre-insertedposition to the inserted position, the body portions 50, 52 slide alongthe interior 32 of the frame member 24. The arcuate configuration of theends 28, 30 facilitates the sliding of the body portions 50, 52 withinthe interior 32 of the frame member 24. If the hinge portion 54 ispresent, then the hinge portion 54 moves toward the bottom wall 26D ofthe frame member 24 as the body portions 50, 52 move from thepre-inserted position to the inserted position. As the body portions 50,52 move from the inserted position to the locked position, the framemember 24 is bent at the notch 34A-34C to form the corner 36 of theframe member 24. If the interlocking portions 74 are present, then theinterlocking portions 74 move toward each other as the body portions 50,52 move from the inserted position to the locked position. If theabutting surfaces 62 are present, the abutting surfaces 62 move towardeach other as the body portions 50, 52 move from the pre-insertedposition toward the locked position.

The method may also comprise the steps of moving the body portions 50,52 of the foldable cornerlock 48 into the pre-inserted position, theinserted position, and the locked position. It is to be appreciated thatthe steps of moving the body portions 50, 52 into the pre-insertedposition, the inserted position, and the locked position may beindependent from one another and each step is not required in themethod. Said differently, the method may only move the body portions 50,52 into one of the pre-inserted position, the inserted position, and thelocked position.

The method may further comprise the step of applying a force F to thefoldable cornerlock 48 to move the body portions 50, 52 from thepre-inserted position toward the inserted position. It is to beappreciated that the step of applying the force F to the foldablecornerlock 48 may be further defined as applying the force F to thehinge portion 54 of the foldable cornerlock 48 to move the body portions50, 52 from the pre-inserted position toward the inserted position.Generally, the force is applied in a direction toward the bottom walls26B of the frame member 224.

While the invention has been described with reference to an exemplaryembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

What is claimed is:
 1. A frame assembly comprising: a frame memberhaving a plurality of walls extending between a first end and a secondend spaced from said first end, with said walls defining an interior ofsaid frame member and also defining at least one notch spaced from saidends of said frame member wherein at least one of said plurality ofwalls is continuous between said ends of said frame member and isbendable at said notch to form a corner of said frame member; at leastone foldable cornerlock comprising first and second body portionsmovable relative to each other for inserting said foldable cornerlockinto said notch of said frame member with said foldable cornerlockfurther comprises at least one arm member spaced from one of said bodyportions thereby defining a gap between said one of said body portionsand said arm member with at least one of said walls of said frame memberdisposed within said gap.
 2. A frame assembly as set forth in claim 1wherein said body portions move between a pre-inserted position wheresaid body portions establish an acute angle relative to each other and alocked position where said body portions establish an right anglerelative to each other.
 3. A frame assembly as set forth in claim 1wherein said foldable cornerlock further comprises a hinge portioncoupling said body portions together and defining an axis extending in alongitudinal direction through said hinge portion, with said bodyportions movable relative to each other by rotation about said axis. 4.A frame assembly as set forth in claim 3 wherein each of said bodyportions have an end spaced from said hinge portion with said endshaving an arcuate configuration for sliding along said interior of saidframe member as said foldable cornerlock is inserted in said notch.
 5. Aframe assembly as set forth in claim 1 wherein said at least one armmember is further defined as a first arm member spaced from said firstbody portion thereby defining a first gap between said first bodyportion and said first arm member, and a second arm member spaced insaid longitudinal direction from said second body portion therebydefining a second gap between said second body portion and said secondarm member, with said first gap receiving one of said walls of saidframe member and said second gap receiving another on of said walls ofsaid frame member.
 6. A frame assembly as set forth in claim 5 whereineach of said body portions of said foldable cornerlock have an exteriorsurface and an opposing interior surface with said first arm memberspaced in said longitudinal direction from said exterior surface of saidbody portions and with said second arm member spaced in saidlongitudinal direction from said interior surface of said body portionsfor allowing the frame member to be disposed between said arm memberswith said arm members covering the walls of the frame member.
 7. A frameassembly as set forth in claim 1 wherein said plurality of walls of saidframe member are further defined as a top wall, a bottom wall spacedopposite from said top wall, an exterior wall interconnecting said topwall and said bottom wall, and an interior wall spaced opposite fromsaid exterior wall and interconnecting said top wall and said bottomwall wherein said bottom wall is continuous over an entire length ofsaid frame member and is bendable at said notch to form said corner ofsaid frame member.
 8. A frame assembly as set forth in claim 1 whereinsaid foldable cornerlock further comprises interlocking portionsconfigured to engage each other for securing said body portions togetherto prevent said body portions from moving relative to each other oncesaid interlocking portions engage each other.
 9. A frame assembly as setforth in claim 8 wherein said interlocking portions comprise a femaleportion defined by said first body portion and a male portion extendingfrom said second body portion configured to mate with said femaleportion to prevent said body portions from separating once saidinterlocking portions engage each other.
 10. A frame assembly as setforth in claim 1 further comprising a fenestration article coupled tosaid frame member.
 11. A frame assembly as set forth in claim 10 furthercomprising a flange extending from said frame member for securing saidfenestration article to said frame member.
 12. A frame assembly as setforth in claim 1 further comprising a coupling cornerlock disposed ineach of the ends of the frame member for coupling said ends of saidframe member together.
 13. A frame assembly as set forth in claim 1wherein said at least one notch is further defined as a first notch, asecond notch, and a third notch defined in said walls with each of saidnotches spaced from each other and from said ends of said frame member,and said at least one foldable cornerlock is further defined as a firstfoldable cornerlock, a second foldable cornerlock, and a third foldablecornerlock disposed in said first, second, and third notches,respectively.
 14. A method of forming a frame assembly for supporting anarticle, the frame assembly comprising a frame member having a pluralityof walls extending between a first end and a second end which is spacedfrom the first end, with the walls defining an interior of the framemember and also defining at least one notch spaced from the ends of theframe member wherein at least one of the plurality of walls iscontinuous between the ends of the frame member, and at least onefoldable cornerlock having first and second body portions movablerelative to each other with at least one arm member spaced from one ofthe body portions thereby defining a gap between one of the bodyportions and the arm member, said method comprising the steps of:forming the at least one notch in the frame member spaced from the endsof the frame member; inserting the foldable cornerlock into the notchsuch that the body portions of the foldable cornerlock extend into theinterior of the frame member; bending the at least one of the pluralityof walls that is continuous between the ends of the frame member at thenotch to define a corner of the frame member; disposing at least one ofthe walls of the frame member within the gap defined between the atleast one arm member and one of the body portions.
 15. A method as setforth in claim 14 further comprising the step of moving the bodyportions of the foldable cornerlock into a pre-inserted position suchthat the body portions establish an acute angle relative to each other.16. A method as set forth in claim 15 wherein the step of inserting thefoldable cornerlock is further defined as positioning the foldablecornerlock within the notch with the body portions in the pre-insertedposition.
 17. A method as set forth in claim 15 further comprising thestep of applying a force to the foldable cornerlock to move the bodyportions from the pre-inserted position toward an inserted position suchthat the body portions are planar relative to each other and the bodyportions slide along the frame member in the interior of the framemember.
 18. A method as set forth in claim 17 further comprising thestep of moving the body portions of the foldable cornerlock from theinserted position toward a locked position where the body portionsestablish a right angle relative to each other as the frame member isbent about the notch of the frame member.
 19. A method as set forth inclaim 18 wherein the foldable cornerlock has interlocking portionsconfigured to engage each other and said method further comprises thestep of forcing the interlocking portions of the foldable cornerlocktogether to retain the foldable cornerlock in the locked position.
 20. Amethod as set forth in claim 14 wherein the foldable cornerlock furtherhas a hinge portion coupling the body portions together and defining anaxis extending in a longitudinal direction through the hinge portion andsaid method further includes the step of rotating the body portions intoa pre-inserted position such that the body portions establish an acuteangle relative to each other.
 21. A method as set forth in claim 14further comprising the step of coupling the ends of the frame membertogether with a coupling cornerlock.
 22. A method as set forth in claim14 wherein the article is further defined as a fenestration article andsaid method further comprises the step of attaching the fenestrationarticle to the frame member.
 23. A method as set forth in claim 14wherein the step of forming at least one notch in the frame member isfurther defined as forming a first notch, a second notch, and a thirdnotch in the frame member with each of the notches spaced from eachother and from the ends of the frame member.
 24. A method as set forthin claim 23 wherein the at least one foldable cornerlock is furtherdefined as a first foldable cornerlock, a second foldable cornerlock,and a third foldable cornerlock and the step of inserting the foldablecornerlock into the notch is further defined as inserting the firstfoldable cornerlock, the second foldable cornerlock, and the thirdfoldable cornerlock into the first notch, the second notch, and thethird notch, respectively, such that the body portions of each of thefoldable cornerlocks extend into the interior of the frame member.
 25. Amethod as set forth in claim 24 wherein the step of bending the framemember about the hinge portion of the foldable cornerlock is furtherdefined as bending the frame member about the hinge portion of each ofthe first cornerlock within the first notch, the second cornerlockwithin the second notch, and the third cornerlock within the third notchto present the frame assembly with a rectangular configuration.